Method of producing a plate-shaped material with a resinous member for a window

ABSTRACT

A method of forming a seat for a fixture for attaching a window to a vehicle in one piece by forming a cavity between a shaping mold and the window and injecting a resinous material for forming the seat into the cavity, wherein a recess is formed at a side surface of the resin molding die; a window is placed on the mold so as to arrange the recess at a position corresponding to an inner peripheral region which is apart by a predetermined distance from the edge of the window thereby forming the cavity in association with the recess and the surface of the window; and the resinous material is injected into the cavity, followed by curing the resinous material, whereby the seat is formed in one piece on the window at the position inside by a predetermined distance from the edge of the window.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method of producing a plate-likematerial for a window, which has a resinous member such as a seat for afixing member which is used when a plate-like material for a window usedfor buildings, vehicles and so on is attached to a flange fitted to awindow opening (hereinbelow, referred to simply as a flange), a seatused for attaching a mirror base for vehicles, a packing made of a resinto be attached to the periphery of an opening to which a wiper for avehicle window is fitted, or the like.

2. Discussion of the Background

The plate-like material for a window (hereinbelow, referred to simply asa plate-like material) is fitted to a flange by interposing sealant suchas urethane between the flange and the plate-like material. There isanother method of attaching the plate-like material to a flange for awindow opening by fitting a clip, a stud bolt or the like to theplate-like material, and inserting the clip or the like to an openingformed in a predetermined position of the flange. In the former case, anadditional clip or provisionally fixing the plate-like material to theflange until the plate-like material is firmly attached to the flange bymeans of the sealant, or an additional clip for positioning theplate-like material at a predetermined position in the flange, issometimes used for the plate-like material. In the later case, awaterproof sealant such as a butyl sealant is used between the flangeand the plate-like material to assure watertightness for the window. Anurethane sealant itself has watertightness.

The member such as the stud bolt, the clip or the like (hereinbelowreferred to as a fixing member in a general term, irrespective ofwhether it is used either for provisionally fixing or permanentlyfixing) used for attaching the plate-like material to the flange may bedirectly attached to the plate-like material as described above, or maybe attached to a frame of synthetic resin which is formed integrallywith a peripheral portion of the plate-like material, whereby theplate-like material is attached to the flange by utilizing the frame.

The attachment of the fixing member to the plate-like material or theframe can be done by interposing a sealant of urethane or the like or adouble-coated tape between the fixing member and the plate-like material(or the frame) at a predetermined position.

Generally, the fixing member is attached to the plate-like material soas to extend in the direction of normal line to the surface of theplate-like material. Accordingly, the orientation of the fixing memberis apt to deflect depending on a curved portion in the plate-likematerial. In order to increase the accuracy of the orientation of thefixing member, the radius of curvature of the curved portion of theplate-like material has to be strictly controlled. Further, a jig andtools for inclusive use have to be prepared in order to attach thefixing member. Further, in a special case, when the orientation of thefixing member is to be changed desirably, it must be contriving theshape of the fixing member itself. In particular, when a plurality offixing members are used, different shapes are needed for the fixingmembers corresponding to the number of use.

In a case of using the urethane sealant for fixing the fixing member tothe plate-like material, it takes a certain time until the urethanesealant is cured. Accordingly, a space for keeping the plate-likematerial fixed fixing member with the urethane sealant is necessary.

On the other hand, when the fixing member is attached to the frame, thefixing member is usually positioned at the interior side of the frame.However, when a sealant having watertightness is additionally usedbetween the plate-like material and the flange, the fixing member ispositioned at the outer side of the sealant. Accordingly, it reducesreliability on the watertightness, and an element for preventing a leakof water, such as a packing is required to assure watertightness. Forthis, it is considered to increase the width of the frame toward theinner side of the plate-like material; to position the fixing member ata position inside the watertight sealant, and to apply the sealantbetween the frame and the flange. However, such method increases thethickness of a window to be formed because of the thickness of thesealant. Further, a large amount of material is necessary for the flangesince the width of the frame is increased toward the inside of theplate-like material.

In order to eliminate the above-disadvantage, there has been proposed toform an extension, as a seat, in the frame so as to extend to the innerside, at only portion where the fixing member is positioned, in order toeliminate an increase in an amount of material for the frame when thefixing member is positioned at the inner side of the watertight sealant.In order to form the frame on a peripheral portion of the plate-likematerial in one piece, the peripheral portion of the plate-like materialis interposed in shaping mold dies for resin molding, and resin isinjected into a cavity formed in the mold. The above-mentioned seat canbe formed integrally with the plate-like material by forming abridge-like introduction passage for resinous material in the mold. Thefixing member is attached to the seat.

However, the portion formed by the bridge-like introduction passage forresin material occupies only a portion in an area which is at a certaindistance from the edge of the plate-like material. Accordingly, it isnot avoidable to produce a step portion between a portion having theextension toward the inner side and the portion without the extension.The step portion produces a gap when the plate-like material is attachedto the flange, whereby a sufficient watertightness cannot be obtained.Further, it is necessary to use a primer for the bridge-like portionwhich is a portion of the flange and the plate-like material before thewatertight sealant is used.

The seat for the fixing member can be formed on the plate-like materialby removing the bridge-like portion after the molding. Then, thewatertight sealant is applied on the surface of the outer side of theseat of the plate-like material. The removal of the bridge-like portionrequires complicated steps by which the plate-like material may bedamaged.

SUMMARY OF THE INVENTION

It is an object of the present invention to eliminate the disadvantagesin the conventional technique.

In accordance with the present invention, there is provided a method offorming a resinous member on a plate-like material for a window in onepiece by forming a cavity between a shaping mold and the plate-likematerial and injecting a resinous material for forming the resinousmember into the cavity, the method being characterized by forming arecess at a side surface of the shaping mold; putting the plate-likematerial with a surface in contact with the side surface so as toarrange the recess at a position corresponding to an inner peripheralregion which is apart by a predetermined distance from the edge of theplate-like material thereby forming the cavity in association with therecess and the surface of the plate-like material; injecting theresinous material into the cavity, and curing the resinous material,whereby the resinous material is formed in one piece on the plate-likematerial at the position inside by the predetermined distance from theedge of the plate-like material.

By the above-mentioned method, it is possible to form in one piece aresinous member such as a seat for the fixing member, a seat for amirror base for vehicles, a packing for a wiper for vehicles or thelike, at a desired position apart by a predetermined distance and inwardfrom the edge of the plate-like material in accordance with the purposeof use. In particular, the position of the resinous member can beprecisely controlled by using a robot.

When the seat for the fixing member is formed, a watertight sealantwhich is used when the plate-like material is attached to the flange canbe applied at an outer portion with respect to the seat, whereby anincrease in the number of elements and an additional working step can beeliminated.

When the frame is formed integrally with a peripheral portion of theplate-like material, a step of removing a bridge-like portion of resinwhich is required in the conventional method, can be eliminated.Further, the elimination of the removing step can reduce a possibilityof damaging the plate-like material.

Generally, a small projection is produced in a molded product at aposition corresponding to the outlet of a resin passage because there isan excessive amount of resin material injected, which is solidifiedafter the curing of it. If the small projection is left at the topsurface of the seat, namely, it is in the same level of the uppersurface of the seat on which the fixing member is to be fixed, a closecontact of the plate-like material to the flange cannot be obtained. Inorder to remove the small projection, a complicated process is required.In the present invention, the resinous material is injected in thecavity, by which the seat has a step portion when molded, from a portioncorresponding to a lower step portion of the seat, whereby a tearingprocess for the small projection formed on the seat becomes unnecessary.

Further, since there is no restriction to the positioning of the fixingmember to the shaping mold, the orientation of the fixing member is freefrom the direction of the normal line of the plate-like material.Accordingly, the fixing member can be directed to a desired directiondepending on a design of the flange and/or the plate-like material. Thefixing members can be attached to the plate-like material at desiredpositions and in desired numbers in accordance with the purpose offixing such as provisional fixing or permanently fixing and the size ofthe plate-like material. Accordingly, there is obtainable a method ofproducing a plate-like material with a fixing member whereby the degreeof freedom in designing of the product is increased.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a schematic view in cross section showing an embodiment of themethod of producing the plate-like material with a resinous memberaccording to the present invention;

FIG. 2 is a schematic view in cross section showing another embodimentof the method of producing a plate-like material with a resinous memberaccording to the present invention;

FIG. 3 is a perspective view schematically showing an embodiment of theplate-like material with a resinous member obtained by the method of thepresent invention;

FIG. 4 is a cross-sectional view of a portion taken along a line A--A inFIG. 3;

FIG. 5 is a schematic view in cross section showing a step of the methodof producing a plate-like material with a resinous member according tothe present invention;

FIG. 6 is a schematic view in cross section showing another step of themethod of producing the plate-like material with a resinous memberaccording to the present invention;

FIG. 7 is a schematic view in cross section showing a still another stepof the method of producing the plate-like material with a resinousmember according to the present invention;

FIG. 8 is a plan view showing an embodiment of the method according tothe present invention wherein a resin molding die is arranged at apredetermined position of a plate-like material;

FIG. 9a is a schematic view in cross section showing another embodimentof the method of producing a plate-like material with a resinous memberaccording to the present invention;

FIG. 9b is a perspective view showing an embodiment of the plate-likematerial obtained by the method shown in FIG. 9a;

FIG. 10 is a schematic view in cross section showing another step in themethod of producing the plate-like material with a resinous memberaccording to the present invention;

FIG. 11 is a schematic view in cross section showing another step in themethod of producing the plate-like material with a resinous memberaccording to the present invention;

FIGS. 12a and 12b are respectively cross-sectional views in crosssection showing different embodiments of the plate-like materialaccording to the present invention; and

FIG. 12c is a plane view of the plate-like material shown in FIG. 12b.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Preferred embodiments of the present invention will be described withreference to the drawings wherein the same reference numerals designatethe same or corresponding parts.

FIG. 1 is a schematic view in cross section showing an embodiment of themethod of attaching a resinous member as a seat for a fixing member to aplate-like material.

In FIG. 1, a shaping mold 30 comprises an upper mold 5, an intermediatemold 6 and a lower mold 7. A resin passage 8 comprising a sprue, arunner and a gate is formed between the upper mold 5 and theintermediate mold 6. A recess 22 is formed in the lower surface of theintermediate mold 6. The recess 22 forms a cavity 33 in association witha surface of the plate-like material 1 when a peripheral portion of theplate-like material 1 is interposed between the intermediate mold 6 andthe lower mold 7. In this case, it is preferable to provide a cushionmeans or packing of a material such as rubber, spring or the like whichis adapted to resiliently hold the plate-like material 1 at a positionof the lower mold 7 in contact with the plate-like material 1. It isfurther preferable to provide an adjusting means 9 of a material such asrubber, spring or the like for absorbing an error in the radius ofcurvature of the plate-like material 1, at a position of theintermediate mold 6 in contact with the plate-like material 1.

The recess 22 has a step portion in a longitudinal cross section,namely, it has a deep portion (a large recess portion) 22a and a shallowportion (a small recess portion) 22b. An outlet of resin passage 11faces the shallow portion 22b. Resinous material is injected in thecavity 33 from the outlet 11 through a resin providing member and theresin passage 8. The fixing member is placed in the deep portion 22a ofthe recess 22.

A fixing member 21 preferably has an upper portion in a substantiallyconical shape or a triangular shape in cross section as a main body forfixing 21a and a bottom portion 21b in a flat plate-like portion. Thus,the flat plate-like portion functions as a cover for defining the upperface of the cavity 33 whereby the invasion of resinous material to anupper portion 22c of the recess 22 where the fixing member 21 is placed,can be prevented. Since the fixing member 21 has the upper portion in asubstantially conical shape or a triangular shape in cross section, themounting of the fixing member 21 in the recess 22 can be secured withouta risk of coming-off.

The fixing member 21 may not have function as a cover, and may havefunction for preventing the flowing of the resinous material to aportion where the fixing member is mounted. It is possible to preventthe flowing of the resinous material with various kinds of means. Themain body portion 21a may have a shape which gradually spreads from thetop to the bottom portion so as to function as a leaf spring, wherebythe coming-off of the fixing member 21 can be prevented, and a shift ofthe fixing member due to a pressure of the resinous material can beprevented. Further, a plurality of openings may be formed in the bottomportion 21b so that the resinous material flows into the openings andsolidifies as shown in FIG. 2. Accordingly, the fixing member 21 canfurther be secured to the seat.

Thus, the fixing member 21 is positioned in the deep portion 22a of therecess 22; the plate-like material 1 is interposed between theintermediate mold 6 and the lower mold 7; the resinous material isinjected into the cavity 33; the resinous material is cured, and then,the plate-like material is removed from the dies, whereby the seat andthe fixing member 21 can be formed integrally with the plate-likematerial 21. However, the plate-like material is not always interposedbetween the intermediate mold 6 and the lower mold 7. For instance, theplate-like material 1 may be mounted on a back-up member (v. FIGS. 5-7),followed by fitting a mold having the same shape as the intermediatemold.

The shape of the recess 33 formed in the resin molding die can bedetermined as desired depending on the shape of the fixing member 21 andthe shape of the flange. Accordingly, it is not always necessary thatthe recess 33 have a substantially stepped portion in a longitudinalcross section as described above. However, it is desirable to form adeep portion and a shallow portion in the recess so that the seat to beproduced has a higher portion and a lower portion since it isunnecessary to conduct post-finishing for the seat formed.

The reason why the post-finishing is unnecessary is as follows.Generally, a small projection is produced in a molded product at aposition corresponding to the outlet of resin passage because anexcessive amount of resinous material injected is left at that position.When the small projection is produced on the top surface of the seat,namely, it is in the same level as a position where the fixing member isattached, the close contact of the plate-like material to the flangecannot be obtained. The removal of the small projection requires anadditional complicated step. If the small projection is formed at aposition lower than the top surface of the seat to which the fixingmember is attached, the post-finishing is unnecessary. Accordingly, itis desirable to form the deep portion and the shallow portion in therecess; to position the fixing member in the deep portion, and to injectthe resinous material from the shallow portion through the outlet ofresin passage. The post-finishing can be eliminated by forming theoutlet of resin passage at a side face of the recess. However, it ispreferable to provide the outlet of resin passage in the shallow portionfrom the standpoint of the fluidity of resin.

The plate-like material obtained by the method of the present inventioncan be used for a front window, a side window, a rear window, a roofwindow or the like in vehicles or a window for buildings. The plate-likematerial may have a flat shape or a curved shape depending on thepurpose of use. As material for the plate-like material, there are aglass plate such as a single plate glass, a layered glass, a laminatedglass wherein a glass plate and a film of synthetic resin are bonded, atransparent organic resin plate, and a plate wherein a plurality ofglass plates and resinous plates are laminated.

In order to improve the bonding property between the plate-like materialand the resinous member, it is desirable to apply a primer treatmentwith use of an adhesive such as a urethane type, an acryl type, a nylontype, a phenol type, a polyester type, a silane type or the like at aposition of the plate-like material at which the resinous member isformed. Further, it is preferable to apply a suitable adhesive to thefixing member in order to increase the bonding characteristic betweenthe fixing member and the resinous member as the seat. On the otherhand, as described before, when a plurality of openings are formed inthe bottom portion 21b, the application of the adhesive to the fixingmember can be omitted. It is because the fixing member can be formedintegrally with the seat by the solidification of the resinous materialunder the condition that the material enters in the openings.

As material for the resinous member in the present invention, there are,for instance, a compound softened by adding an additive such asplasticizer to a mixture, as a base resin comprising at least one in agroup of polyvinyl chloride, a copolymer of vinyl chloride and ethylene,a copolymer of vinyl chloride and vinyl acetate, a copolymer of vinylchloride and propylene and a copolymer of vinyl chloride, ethylene andvinyl acetate. Further, another thermoplastic resin may be blended toincrease the fluidity. As the thermoplastic resin to be blended, thereis a chlorinated polyethylene resin, a urethane-modified vinyl chlorideresin, a urethane resin, a polyester resin, a acrylic resin, rubberincluding polyester elastomer, NBR or SBR, EVA or ABS. Suchthermoplastic resins may be used alone or in combination as a mixture oftwo or more of them.

The material is introduced into the cavity by an ordinary injectionmolding method to obtain a molded product. Further, a reactive injectionmolding method may be employed with the use of a reactive urethaneresin. Further, a thermoset resin may be used. However, it is preferableto use the above-mentioned thermoplastic resin because it is possible toemploy a hot runner system for reducing an amount of resin in the resinpassage and to use the material again.

A frame of synthetic resin may be formed integrally with the plate-likematerial at its peripheral portion, the frame being interposed betweenthe flange and the plate-like material. When the frame is formed withthe same material as the seat, a second cavity is formed at an outerposition in the plate-like material with respect to the recess of theshaping mold, whereby the frame can be formed integrally with theplate-like material at the same time of forming the seat by injectingthe resinous material into the second cavity at the same time ofinjecting the resinous material into the first cavity which is formed inassociation with the recess and the plate-like material.

FIG. 2 shows the above-mentioned embodiment. A resin molding die 40comprising an upper mold 5, an intermediate mold 6 and lower mold 7wherein a resin passage 8 having a sprue, a runner and a gate is formedbetween the upper mold 5 and the intermediate mold 6. A recess 22 isformed in the lower surface of the intermediate mold 6 so that a cavity33 is formed in association with the recess 22 and a surface of theplate-like material 1 when a peripheral portion of the plate-likematerial 1 which is a curved single-layered glass plate is interposedbetween the intermediate mold 6 and the lower mold 7. Further, a secondcavity 31 is formed at a position corresponding to an outer peripheralportion of the recess 22. The cavity 31 is defined in association withthe inner wall of the intermediate mold 6, the inner wall of the lowermold 7 and the peripheral portion of the plate-like material 1 incorrespondence to the outer periphery of the plate-like material 1.

In the same manner as the embodiment shown in FIG. 1, the recess 22 hasa substantially step-like portion in its longitudinal cross section,namely, the recess 22 has a deep portion 22a and a shallow portion 22b.The fixing member 21 is positioned in the deep portion of the recess 22.An outlet of resin passage 11 is provided at the shallow portion, fromwhich resin is injected into the cavity 33. On the other hand, a secondoutlet of resin passage 12 is provided at an inner wall portion of thesecond cavity 31 in the intermediate mold 6. Resin is injected in thesecond cavity 31 through the second outlet of resin passage 12 at thesame time of the extrusion of resin through the outlet of resin passage11.

Thus, the fixing member 21 is positioned in the deep portion of therecess 22; the plate-like material 1 is interposed between theintermediate mold 6 and the lower mold 7, and resin is injected into thecavities 33, 31 followed by solidifying. After the solidification of theresin, the intermediate mold 6 and the lower mold 7 are released.Portions of solidified resin at the outlets 11, 12 are removed bytearing, and the plate-like material 1 is taken out from the shapingmold. Thus, the plate-like material formed integrally with the frame andthe seat having the fixing member can be obtained. In this embodiment,it is unnecessary to conduct post-finishing for the resin portions whichhave been left even by tearing.

FIG. 3 is a perspective view showing an embodiment of the plate-likematerial with the fixing member produced in accordance with the above,and FIG. 4 is a cross-sectional view taken along a line A--A in FIG. 3.A frame 3 of synthetic resin is formed integrally with a peripheralportion of the plate-like material 1. At the inner side of the frame 3,a seat 2 and a fixing member 21 firmly attached to the seat 2 are formedintegrally with an interior side of the plate-like material 1.

In a case when the plate-like material with the fixing member is used asa fixed window for a vehicle, the fixing member 21 is inserted to aposition-determining opening formed at a predetermined position in aflange of the vehicle, whereby the plate-like material 1 can bepositioned correctly to the flange. In this case, a watertight sealant 4is applied between the frame 3 of the plate-like material 1 and the seat2 to which the fixing member is attached. Thus, the plate-like materialwith the fixing member is attached to the flange.

When the fixing member 21 itself has the function of function tosecuring the plate-like material 1 to the flange (like a stud bolt), abutyl sealant or the like is used as the watertight sealant. On theother hand, when the fixing member 21 does not have a sufficientsecuring force, an urethane sealant or the like is used as thewatertight sealant. In the later case, the fixing member 21 has thefunction of temporarily securing the plate-like material 1 to apredetermined position of the flange until the urethane sealant issolidified to permanently fix the plate-like material to the flange. Assuch a fixing member, a clip made of synthetic resin such as polyacetalor the like may be used although there is no limitation of it.

A generally used shaping mold made of metal can be used as theabove-mentioned shaping mold. An inexpensive mold made of a hightemperature resistant resin may also be used in consideration of lot anda pressure of injecting resin material. In the above-mentionedembodiments, the shaping mold comprises three mold portions. However, itmay consist of two mold portions, and it can be used depending onrequirements of the structure such as the sprue, the runner, the gateand so on.

In the embodiment shown in FIG. 2, the resin material in the same resinpassage is branched and fed to separate portions for the seat and theframe. However, the resin material may be injected through separateresin passages in a case that the seat and the frame after molding havedifferent hardness, physical properties and so on.

Although there is no special restriction in the shape of the outlets ofthe resin passage, it is preferable that the diameter of the resinpassage outlets is 2 mm or less in order to cut the resin portion of theresin passage from the shaped product after the solidification of theresin material, and unnecessitate the post-finishing of the shapedsurface.

FIGS. 5 through 7 show another embodiment of forming the seat on theplate-like material.

A shaping mold 50 has a mold portion having a recess 22 and a resinproviding member 51. The shaping mold 50 is connected to a robot 60 at aportion of the resin providing member 51. The position where the robotsupports the shaping mold 50 can be determined depending on the drivingmechanism of the robot and a position where resin material is molded.

The robot can move the shaping mold 50 so that the recess 22 is broughtto a predetermined position of the plate-like material 1. Then, thesurface having the recess 22 is brought to contact with the plate-likematerial 1 at the position, whereby a cavity 53 is formed between theplate-like material 1 and the recess 22.

In the same manner as the embodiment shown in FIG. 1, the recess 22 hasa substantially step-like shape in its longitudinal cross section,namely, it has the deep portion 22a and the shallow portion 22b. Theoutlet of resin passage 11 is formed at the shallow portion so that theresin material is injected into the cavity 53 through the outlet ofresin passage 11 of the resin providing member 51. Further, the fixingmember 21 is positioned in the deep portion 22a of the recess 22.

A back-up member 55 is preferably disposed on the surface of theplate-like material 1 at the opposite side of the shaping mold 50 so asto prevent the plate-like material from deflecting or breaking due to apressure of the resin material injected.

FIG. 8 is a plane view showing a method of arranging the resin moldingdie at a predetermined position on the plate-like material in theabove-mentioned embodiment.

First, the plate-like material, the shaping mold and the resin providingmember are arranged at predetermined positions. The plate-like material1 is transferred by a conveyor 81 which is driven at predetermined timeintervals to a position-determining station 83 where aposition-determining stopper, a pusher 84 and so on are operated,whereby the plate-like material 1 is placed at a predetermined correctposition. In this case, a bonding material 85 such as an adhesive layer,a primer layer, a double-coating tape or the like may be provided in anarea for forming the resinous member on the plate-like material 1.

When the determination of position of the plate-like material 1 isfinished, the shaping mold and/or the resin providing member 86 isbrought to a predetermined position by means of the robot 80. Instead ofthe stopper and/or the pusher 84, another fixing means such as a vacuumabsorbing chuck may be used to fix the plate-like material 1.

When the fixing member is mounted on a resinous member 87 to be shapedbefore the shaping mold is set at a predetermined position, a desiredelement should be put in the mold in an element attaching station 88.

It is desirable that the lower surface of the mold is in close contactwith the surface of the plate-like material. However, a gap is sometimesproduced between the plate-like material and the lower surface of thedie due to a slightly curved portion or unevenness in the surface of theplate-like material. Accordingly, it is preferable to provide aresilient member (not shown), which is durable to heat of molten resin,on the surface of the die in contact with the plate-like material,whereby there is no danger of producing a gap between the mold and theplate-like material. It is difficult in practice to obtain a completecontact between them due to a pressure of the resin extruded or injectedand an amount of the resin. Accordingly, the production of fins at anedge or edges of the resinous member is unavoidable. In order tominimize the production of fins, a clearance of 0.3 mm or less should beformed in the contacting surface between the die and the plate-likematerial.

In this embodiment, the conveyor serves as the back-up member as shownin FIGS. 5-7.

The plate-like material is held in close contact between the shapingmold and the back-up member. Then, a screw 57 in the resin provingmember 51 is rotated by driving a motor 51, and resinous material moltenin a heat cylinder 58 is extruded or injected into the cavity 53 throughthe outlet of resin passage 11.

The extrusion or injection of the resinous material is automaticallycontrolled by a computer operating in association with meters such anammeter, a volt meter and so on provided for the motor 56. When theextrusion or injection of the resinous material has been completed andthe temperature of the resin molding die has reduced to a predeterminedtemperature or less, the resin providing member is raised from thesurface of the plate-like material 1, and a resinous member 70 is formedat a predetermined position of the plate-like material 1 as shown inFIG. 7.

The plate-like material with the resinous member 70 is removed from theposition-determining station 83 by means of the conveyor 81, and thenext plate-like material 1 is transferred to the position-determiningstation 83. The above-mentioned operation is repeated, as shown in FIG.8.

As another way, only the mold portion may be held by the robot so as tobe moved to a desired position, and the mold portion is connected to theresin providing member by means of a heat-resistant hose. With such anarrangement, the mold portion can be easily moved to a correct positionsmoothly.

Next, an embodiment of forming another member other than the seat, asthe resinous member of the present invention, to the plate-like materialwill be described with reference to FIGS. 9 through 11.

The plate-like material 1 has an opening 13 in an area where theresinous member is formed. A shaping mold comprises a pair of upper andlower die portions 90, 90'. The plate-like material 1 is interposedbetween the pair of mold portions 90, 90' so as to include therein theopening 13, whereby a cavity 93 is formed in association with eachrecess 22 in the pair of mold portions 90, 90' and the plate-likematerial 1. Thus, the resinous member is formed in the cavity 93. Inthis embodiment, a suitable element 94 which functions as a fixing tablefor various devices such as wipers for an automobile may be provided inthe cavity 93. FIG. 12 shows a resinous member 99 having the element 94which traverses the surface of the plate-like material 1.

The element 94 may be so provided as to be withdrawn from the resinousmember 99, whereby the resinous member 99 is formed only the peripheralportion of the opening of the plate-like material 1. In this case, theresinous member 99 performs as a packing for improving watertightnessand holding performance in a case of attaching the wipers. Thus, theplate-like material having an opening 95 of a predetermined diameteraround which is covered by resinous material can be formed.

As another embodiment of the resinous member, there is a seat for aninternal mirror such as a back mirror, a room mirror or the like whichis attached to a front glass or the like of a vehicle. The internalmirror is supported by a mirror base attached to the inner surface ofthe front glass. The mirror base is generally made of metal such asstainless steel. Accordingly, an adhesive agent is applied between themirror base and the front glass. A layer of the adhesive agent shouldhave a sufficient thickness to absorb vibrations when the vehicle isdriven, whereby the dropping of the internal mirror can be preventedduring the cruise.

The adhesive agent should have good performance such as a sufficientbonding strength between the mirror base and the front glass, easinessof bonding operation, and elasticity after bonding. In some cases, arequirement of making the bonding operation easy may reduce the othercharacteristics. With use of the method of the present invention to formthe seat integrally with the mirror base at a predetermined position ofthe front glass, the operation can be easy. In this case, by injecting aselected resinous material capable of absorbing vibrations in therunning of the vehicle into the cavity formed in association with therecess of the shaping mold and the front glass, the mirror base can beeasily formed on the front glass without sacrificing the above-mentionedbonding characteristics, the easiness of bonding operation and theelasticity after bonding.

Further, the seat to be formed may have an engaging portion so as tofacilitate the mechanically joining of it to the mirror base.

What is claimed is:
 1. A method of forming a resinous member on aplate-shaped material for a window in one piece, the method comprisingthe steps of:forming a recess at a side surface of a shaping mold;placing a surface of the plate-shaped material in contact with the sidesurface of the shaping mold, so that the recess is positioned at aninner peripheral region of the plate-shaped material which is spacedapart by a predetermined distance from an edge of the plate-shapedmaterial, and the recess forms a cavity between the shaping mold and theplate-shaped material which is spaced by said predetermined distancefrom said edge of said plate-shaped material; injecting or extruding aresinous material for forming the resinous member into the cavity; andcuring the resinous material to form the resinous member, wherein theresinous material is formed in one piece on the plate-shaped material atsaid position spaced by said predetermined distance from the edge of theplate-shaped material, said resinous member serves as a seat for afixing member for attaching the plate-shaped material to a frame or aflange for a window, and the recess has at least two portions ofdifferent depth; the method comprising the further steps of: positioningthe fixing member in a deep recess portion of said at least twoportions; and injecting or extruding the resinous material into thecavity from a shallow recess portion of said at least two portions. 2.The method according to claim 1, wherein the shaping mold comprises twomold portions at least one of which has said recess, said methodcomprising the further step of interposing a peripheral portion of theplate-shaped material between the two mold portions whereby the cavityis formed in association with the recess and the plate-shaped material.3. The method according to claim 2, wherein at least one of the moldportions has an inner wall for providing a second cavity at a positionapart by a predetermined distance and outward from a second cavity, andsaid method comprises the further steps of injecting the resinousmaterial into the second cavity formed in association with the innerwall and the peripheral portion of the plate-shaped material; and curingthe resinous material, whereby a frame member is formed integrally withthe plate-shaped material at its peripheral portion.
 4. The methodaccording to claim 1, comprising the further steps of supporting theshaping mold by an arm of a robot; moving the shaping mold to theplate-shaped material so that the surface having the recess is broughtto a predetermined position of the plate-shaped material; and injectingor extruding the resinous material into the recess, wherein the resinousmember is formed at a predetermined position.
 5. The method according toclaim 4, wherein an opening is formed in the plate-shaped material, andthe shaping mold comprises two mold portions; the method comprising thefurther steps of moving one of the mold portions having a first recessto the plate-shaped material to surround the opening by the firstrecess; moving another mold portion having a second recess to theplate-shaped material at a position where the second recess is adjacentto the first recess; and interposing the plate-shaped material betweenthe two mold portions.
 6. A method of forming a resinous member on aplate-shaped material for a window in one piece, the method comprisingthe steps of:forming a recess at a side surface of a shaping mold;placing a surface of the plate-shaped material in contact with the sidesurface of the shaping mold, so that the recess is positioned at aninner peripheral region of the plate-shaped material which is spacedapart by a predetermined distance from an edge of the plate-shapedmaterial, and the recess forms a cavity between the shaping mold and theplate-shaped material which is spaced by said predetermined distancefrom said edge of said plate-shaped material; injecting or extruding aresinous material for forming the resinous member into the cavity;curing the resinous material to form the resinous member, wherein theresinous material is formed in one piece on the plate-shaped material atsaid position spaced by said predetermined distance from the edge of theplate-shaped material; and positioning a fixing member at a bottom ofthe recess to define a wall in the cavity by means of a bottom surfaceof the fixing member; wherein said injecting step comprises the step of:injecting or extruding a resinous material into the cavity such that thewall of the fixing member prevents the resinous material from flowinginto a space in the cavity having the fixing member, the resinous memberserving as a seat for the fixing member for attaching the plate-shapedmaterial, and the fixing member formed integrally with the seat isattached to the surface of the plate-shaped material.